Over the past two years, EPV has directed its manufacturing research efforts toward enhancing the productivity of its tandem amorphous silicon (a-Si) photovoltaic module process. One major area of focus has been on streamlining the process to reduce the amount of time and complexity to manufacture a module by eliminating or combining process steps. In addition, significant effort has been put into improving the performance of the standard a-Si tandem module. This work has identified and developed process changes that have lead to a -20% increase in module power, with the largest contributors being the implementation of a zinc oxide/aluminum back reflector and significant increases of active area. As a result of these productivity and process improvements, the direct manufacturing cost per watt of an EPV module in the New Jersey facility has decreased by over 27%.